Method of manufacturing a handheld computing device

ABSTRACT

A handheld computing device and handheld music player are disclosed. The handheld computing device includes a seamless enclosure formed from an extruded tube. The extruded tube includes open ends and internal rails which serve as a guide for slidably assembling an operational assembly through the open ends of the extruded tube, a reference surface for positioning the operational assembly relative to an access opening in the seamless enclosure, and a support structure for supporting the operational assembly during use. The handheld music player includes an elongated extruded tube extending along a longitudinal axis. The elongated extruded tube has a first open end and a second open end opposite the first open end, and defines an internal lumen which is sized and dimensioned for slidable receipt of operational components of the handheld music player. The lumen includes rails for guiding the operational components to their desired position within the lumen.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of, and claims the benefit ofpriority under 35 U.S.C. §120 to, co-pending U.S. patent applicationSer. No. 12/685,463, filed Jan. 11, 2010, entitled “HANDHELD COMPUTINGDEVICE,” which is a Continuation of U.S. patent application Ser. No.12/395,570, filed Feb. 27, 2009, entitled “HANDHELD COMPUTING DEVICE,”now U.S. Pat. No. 7,649,744, which issued Jan. 19, 2010, which is aDivisional of U.S. patent application Ser. No. 10/884,172, filed Jul. 2,2004, entitled “HANDHELD COMPUTING DEVICE,” now U.S. Pat. No. 7,515,431,which issued Apr. 7, 2009, all of which are hereby incorporated hereinby reference.

This application is also related to the following United States PatentApplications, all of which are hereby incorporated herein by reference:U.S. patent application Ser. No. 12/412,108, filed Mar. 26, 2009,entitled “HANDHELD COMPUTING DEVICE,” now U.S. Pat. No. 7,839,646,issued Nov. 23, 2010; U.S. patent application Ser. No. 29/196,832, filedJan. 5, 2004, entitled “MEDIA DEVICE,” now abandoned; U.S. patentapplication Ser. No. 10/643,256, filed Aug. 18, 2003, entitled “MOVABLETOUCH PAD WITH ADDED FUNCTIONALITY,” now U.S. Pat. No. 7,499,040, issuedMar. 3, 2009; U.S. patent application Ser. No. 10/188,182, filed Jul. 1,2002, entitled “TOUCH PAD FOR HANDHELD DEVICE,” now U.S. Pat. No.7,046,230, which issued May 16, 2006; U.S. application Ser. No.10/722,948, filed Nov. 25, 2003, entitled “TOUCH PAD FOR HANDHELDDEVICE,” now U.S. Pat. No. 7,495,659, which issued Feb. 24, 2009 andU.S. application Ser. No. 10/423,490, filed Apr. 25, 2003, entitled“MEDIA PLAYER SYSTEM,” now U.S. Pat. No. 7,627,343, which issued Dec. 1,2009.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to portable computing devices.More particularly, the present invention relates to enclosures ofportable computing devices and methods of assembling portable computingdevices.

2. Description of the Related Art

In recent years, portable computing devices such as laptops, PDAs, mediaplayers, cellular phones, etc., have become small, light and powerful.One factor contributing to this phenomenon is in the manufacturer'sability to fabricate various components of these devices in smaller andsmaller sizes while in most cases increasing the power and or operatingspeed of such components. Unfortunately, the trend of smaller, lighterand powerful presents a continuing design challenge in the design ofsome components of the portable computing devices.

One design challenge associated with the portable computing devices isthe design of the enclosures used to house the various internalcomponents of the portable computing devices. This design challengegenerally arises from two conflicting design goals—the desirability ofmaking the enclosure lighter and thinner, and the desirability of makingthe enclosure stronger and more rigid. The lighter enclosures, whichtypically use thinner plastic structures and fewer fasteners, tend to bemore flexible and therefore they have a greater propensity to buckle andbow when used while the stronger and more rigid enclosures, whichtypically use thicker plastic structures and more fasteners, tend to bethicker and carry more weight. Unfortunately, increased weight may leadto user dissatisfaction, and bowing may damage the internal parts of theportable computing devices.

Furthermore, in most portable computing devices, the enclosures aremechanical assemblies having multiple parts that are screwed, bolted,riveted, or otherwise fastened together at discrete points. For example,the enclosures typically have included an upper casing and a lowercasing that are placed on top of one another and fastened together usingscrews. These techniques typically complicate the housing design andcreate aesthetic difficulties because of undesirable cracks, seams, gapsor breaks at the mating surfaces and fasteners located along thesurfaces of the housing. For example, a mating line surrounding theentire enclosure is produced when using an upper and lower casing. Notonly that, but assembly is often a time consuming and cumbersomeprocess. For example, the assembler has to spend a certain amount oftime positioning the two parts and attaching each of the fasteners.Furthermore, assembly often requires the assembler to have special toolsand some general technical skill.

Another design challenge is in techniques for mounting structures withinthe portable computing devices. Conventionally, the structures have beenlaid over one of the casings (upper or lower) and attached to one of thecasings with fasteners such as screws, bolts, rivots, etc. That is, thestructures are positioned in a sandwich like manner in layers over thecasing and thereafter fastened to the casing. This methodology suffersfrom the same drawbacks as mentioned above, i.e., assembly is a timeconsuming and cumbersome.

In view of the foregoing, there is a need for improved enclosures forportable computing devices. Particularly, enclosures which are more costeffective, smaller, lighter, stronger and aesthetically more pleasingthan current enclosure designs. In addition, there is a need forimprovements in the manner in which structures are mounted within theenclosures. For example, improvements that enable structures to bequickly and easily installed within the enclosure, and that helpposition and support the structures in the enclosure.

SUMMARY OF THE INVENTION

The invention relates, in one embodiment, to a handheld computingdevice. The computing device includes a seamless enclosure formed froman extruded tube. The extruded tube includes open ends and internalrails which serve as a guide for slidably assembling a user interfaceassembly through the open ends of the extruded tube, a reference surfacefor positioning the user interface assembly relative to an accessopening in the seamless enclosure, and a support structure forsupporting the user interface assembly during use.

The invention relates, in another embodiment, to a method of assemblinga handheld computing device. The method includes providing an enclosureformed from an extruded tube including open ends and internal rails. Themethod also includes providing operational components for performingoperations associated with the handheld computing device. The methodfurther includes inserting the operational components into the extrudedtube through an open end of the extruded tube. The operationalcomponents slide along the internal rail during insertion. The internalrails also help to locate the operational components in their desiredposition within the extruded tube. The method additionally includessecuring the operational components to the extruded tube.

The invention relates, in another embodiment, to a handheld musicplayer. The hand held music player includes an elongated extruded tubeextending along a longitudinal axis, and having a first open end and asecond open end opposite the first open end. The elongated extruded tubedefines an internal lumen which is sized and dimensioned for slidablereceipt of operational components of the handheld music player. Thelumen includes rails for guiding the operational components to theirdesired position within the lumen.

The invention relates, in another embodiment, to a handheld computingdevice. The handheld computing device includes a seamless enclosurehaving a substantially planar front surface. The planar front surface isconfigured to present a user interface sub system of the handhelddevice. The seamless enclosure is formed from an extruded tube havingopen ends and internal rails. The open ends are configured to receivethe user interface sub system therethrough during assembly of thehandheld device. The internal rails are configured to locate the userinterface sub system in its desired position relative to the planarfront surface of the enclosure during assembly of the handheld computingdevice.

The invention relates, in another embodiment, to a method ofmanufacturing a handheld computing device. The method includes formingan enclosure for the handheld device. The formation includes at leastextruding a tube with a substantially planar surface and internal railsand cutting the tube to a desired length where the cutting operationproduces openings at each end of the tube. The method also includesforming one or more holes in the substantially planar surface. Themethod further includes inserting a display assembly into the tubethrough one of the openings. The display assembly includes asubstantially planar printed circuit board and a display. The printedcircuit board slides along the internal rails during insertion. Theinternal rails locate the display behind a first hole and adjacent theplanar surface of the tube. The method additionally includes inserting aplanar input device into the tube through one of the openings. Theplanar input device slides along the internal rails during insertion.The internal rails locate the input device behind a second hole andadjacent the planar surface of the tube.

The invention relates, in another embodiment, to a planar retainingplate. The retaining plate includes a body. The retaining plate alsoincludes a first set of flexure arms extending from a first side of thebody and a second set of flexure arms extending from a second side ofthe body opposite the first side. Each of the flexure arms areconfigured for insertion into a different slot located on a deviceenclosure in order to secure the retaining plate to the deviceenclosure. The retaining plate serves as a reference surface to variouscomponents located internal or external to the device enclosure.

The invention relates, in another embodiment, to an interface assemblyof a handheld computing device. The handheld computing device has anenclosure and a first electronic device contained therein. The interfaceassembly includes a printed circuit board (PCB) divided into a flexureportion, a first base portion and a second base portion. The flexureportion is positioned between the first and second base portions. Theflexure portion allows the first base portion to move relative to thesecond base portion. The second base portion is attached to the firstelectronic device. The interface assembly also includes a secondelectronic device attached to the first base portion, and operativelycoupled to the first electronic device. The interface assembly furtherincludes a support plate attached to the second electronic device. Theflexure portion is configured to flex so that the first base portionshifts relative to the second base portion thereby allowing the plate tobe correctly aligned with the enclosure during assembly of the handheldcomputing device.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be readily understood by the following detaileddescription in conjunction with the accompanying drawings, wherein likereference numerals designate like structural elements, and in which:

FIG. 1 is an exploded perspective diagram of an electronic device, inaccordance with one embodiment of the present invention.

FIG. 2 is a perspective diagram of a handheld computing device, inaccordance with one embodiment of the present invention.

FIG. 3A is a diagram of an assembled hand held computing device, inaccordance with one embodiment of the present invention.

FIG. 3B is a diagram of the hand held computing device of FIG. 3A in itsunassembled form, in accordance with one embodiment of the presentinvention.

FIG. 4 is top view diagram, in cross section, of an assembled hand heldcomputing device, in accordance with one embodiment of the presentinvention.

FIG. 5 is bottom view diagram, in cross section, of the assembled handheld computing device, in accordance with one embodiment of the presentinvention.

FIGS. 6A-6C show the insertion and mounting of an input assembly insidea seamless enclosure, in accordance with one embodiment of the presentinvention.

FIGS. 7A and 7B show a bottom plate in its unassembled and assembledpositions, in accordance with one embodiment of the present invention.

FIGS. 8A-8C are diagrams illustrating the audio subassembly inaccordance with one embodiment of the present invention.

FIG. 9A is a front perspective view of a seamless enclosure, inaccordance with one embodiment of the present invention.

FIG. 9B is a rear perspective view of a seamless enclosure, inaccordance with one embodiment of the present invention.

FIG. 9C is a front view of a seamless enclosure, in accordance with oneembodiment of the present invention.

FIG. 9D is a rear view of a seamless enclosure, in accordance with oneembodiment of the present invention.

FIG. 9E is a top view of a seamless enclosure, in accordance with oneembodiment of the present invention.

FIG. 9F is a bottom view diagram of a seamless enclosure, in accordancewith one embodiment of the present invention.

FIG. 9G is a right side view of a seamless enclosure, in accordance withone embodiment of the present invention.

FIG. 9H is a left side view of a seamless enclosure, in accordance withone embodiment of the present invention.

FIG. 10 is a method of manufacturing an electronic device, in accordancewith one embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The invention generally pertains to portable computing devices and moreparticularly to components of and methods for assembling portablecomputing devices. One aspect of the invention relates to a seamlessenclosure that includes open ends and internal rails which serve as aguide for slidably assembling the internal components of the portablecomputing devices through the open ends of the seamless enclosure, aswell as positioning and supporting the internal components in theirassembled position within the seamless enclosure. The seamless enclosuremay for example be formed via an extrusion process. Another aspect ofthe invention relates to a planar retaining plate, which serves as amulti-positional reference surface to various components of the portablecomputing devices. The retaining plate may for example be assembledwithin the lumen of the seamless enclosure to provide a referencesurface to internal and external parts of the portable computing device.Another aspect of the invention relates to assemblies capable of flexingin order to align interfacing parts. For example, aligning a platewithin the lumen of the seamless enclosure. Yet another aspect of theinvention relates to a method of manufacturing a portable computingdevice. The method may include extruding a tube with a substantiallyplanar surface and internal rails, cutting the tube to a desired length,forming one or more access openings in the substantially planar surface,sliding the user interface assembly along the internal rails into thetube, and thereafter locating and supporting the user interface assemblybehind an access opening and adjacent the planar surface of the tube viathe internal rails.

These and other embodiments of the invention are discussed below withreference to FIGS. 1-10. However, those skilled in the art will readilyappreciate that the detailed description given herein with respect tothese figures is for explanatory purposes as the invention extendsbeyond these limited embodiments.

FIG. 1 is an exploded perspective diagram of an electronic device 50, inaccordance with one embodiment of the present invention. The device 50may be sized for one-handed operation and placement into small areassuch as a pocket, i.e., the device 50 can be a handheld pocket sizedelectronic device. By way of example, the electronic device 50 maycorrespond to a computer, media device, telecommunication device and/orthe like.

The device 50 includes a housing 52 that encloses and supportsinternally various electrical components (including for exampleintegrated circuit chips and other circuitry) to provide computingoperations for the device 50. The housing 52 also defines the shape orform of the device 50. That is, the contour of the housing 52 may embodythe outward physical appearance of the device 50. The housing 52generally includes a main body 54 in the form of an integral tube. Byintegral, it is meant that the main body is a single complete unit. Bybeing integrally formed, the main body has a substantially seamlessappearance, which is unlike conventional housings, which include twoparts that are fastened together thereby forming a seam therebetween.Because of the tube like configuration, the main body 54 defines acavity 56 therethrough between a first open end 58 and second open end60 located opposite the first open end 58. The main body 54 alsoincludes one or more windows 62, which provide access to the electricalcomponents, particularly the user interface elements, when they areassembled inside the cavity 56 of the main body 54.

In order to seal the main body 54, the housing 52 additionally includesa pair of end caps 64A and 64B. Each of the end caps 64 is configured tocover one of the open ends 58 or 60 thereby forming a fully enclosedhousing system. The end caps 64 may be formed from similar or differentmaterials as the main body 54. Furthermore, the end caps 64 may beattached to the main body 54 using a variety of techniques, includingbut not limited to, fasteners, glues, snaps, and/or the like. In somecases, the end caps 64 may be positioned on the surface of the open ends58 and 60. If so, they typically have the same shape as the outerperiphery of the main body 54. In order to eliminate gaps, cracks orbreaks on the front and side surfaces, the end caps 64 may alternativelybe placed inside the cavity 56 at each of the ends. In this arrangement,the outer periphery of the end cap 64 generally matches the innerperiphery of the main body 54. This implementation is typicallypreferred in order to form a housing 52 with a uniform and seamlessappearance, i.e., no breaks when looking directly at the front, back orside of the housing.

The cross sectional shape, including both the outer and inner shapes, ofthe main body 54 may be widely varied. They may be formed from simple orintricate shapes whether rectilinear and/or curvilinear. For hand helddevices, it is typically preferred to use a shape that better fits thehand (e.g., form fits). By way of example, a rectangle with curved edgesor an oval or pill shaped cross section having curvature that moreeasily receives the hand may be used. It should be noted that the innercross sectional shape may be the same or different from the externalcross sectional shape of the main body. For example, it may be desirableto have a pill shaped external and a rectangularly shaped interior, etc.In addition, although not a requirement, the front surface of the mainbody 54 may be substantially planar for placement of the user interfaceof the device 50.

The device 50 also includes one or more electronic subassemblies 66. Thesubassemblies 66 each include a carrier 68 and one or more operationalcomponents 70 of the electronic device 50. The carrier 68 provides astructure for carrying the operational components 70 and supporting themwhen assembled inside the housing 52. By way of example, the carrier 68may be formed from plastics, metals and/or a printed circuit board(PCB). The operational components 70, on the other hand, performoperations associated with the computing device 50. The operationalcomponents 70 may for example include user interface elements 70A and/orcircuit elements 70B. The user interface elements 70A allow a user tointeract with the computing device 50. By way of example, the userinterface elements 70A may correspond to a display and/or an inputdevice such as a keypad, touch pad, touch screen, joystick, trackball,buttons, switches and/or the like. The circuit components 70B, on theother hand, perform operations such as computing operations for thecomputing device 50. By way of example, the computing components 70B mayinclude a microprocessor, memory, hard drive, battery, I/O connectors,switches, power connectors, and/or the like.

During assembly, the subassemblies 66 are positioned inside the cavity56 of the main body 54. In particular, the subassemblies 66 are insertedinto one of the open ends 58 or 60 of the main body 54 mainly along alongitudinal axis 74 of the main body 54 to their desired positionwithin the housing 52. Once positioned inside the cavity 56, the endcaps 64 of the housing 52 may be attached to the main body 54 in orderto fully enclose the housing 52 around the subassemblies 66. In mostcases, the user interface elements 70A are positioned relative to thewindow opening 62 so that a user may utilize the user interface elements70A. By way of example, the window 62 may allow viewing access to adisplay or finger access to a touch pad or button.

In order to more efficiently assemble the electronic subassemblies 66inside the cavity 56, the device 50 includes an internal rail system 78disposed inside the cavity 56 of the main body 54. In most cases, theinternal rail system 78 is integrally formed with the main body 54,i.e., formed as a single part. The internal rail system 78 is configuredto receive the various subassemblies 66 and guide them to their desiredposition within the main body 54 when the subassemblies 66 are insertedthrough one of the open ends 58 or 60. The internal rail system 78enables the subassemblies 66 to be easily and quickly assembled withinthe device 50. For example, the rail system 78 provides for insertion(or removal) with minimal effort and without tools. The internal railsystem 78 also helps support and store the subassemblies 66 in anorganized manner within the device 50. By way of example, the railsystem 78 may store the subassemblies 66 in a stacked parallelarrangement thereby using available space more efficiently.

As shown, the rail system 78 includes at least one set of opposed rails80, each of which extends longitudinally through the cavity 56 and eachof which protrudes from the inner sides of the main body 54. The rails80 are configured to receive the subassembly 66 and cooperate to guidesubassemblies 66 to their desired position within the housing 52. Theinternal rails 80 generally allow the subassemblies 66 to be slid intothe cavity 56 through the open ends 58 or 60 following the longitudinalaxis 74 of the main body 54. That is, the subassemblies 66 and moreparticularly the carrier 68 are capable of sliding in and out of thehousing 52 along one or more surfaces of the rails 80.

The portion of the subassemblies 66 that engages the rails 80 may be asurface of the subassemblies or alternatively one or more posts ormounts that extend outwardly from the subassemblies 66. Furthermore, thereference surfaces for the opposed rails 80 may be positioned in thesame plane or they may be positioned in different planes. Theconfiguration generally depends on the configuration of thesubassemblies 66. By way of example, in some cases, the subassemblies 66may have a cross section that is stepped rather than completely planar.In cases such as these, the opposed rails 80 have references surfaces indifferent planes in order to coincide with the stepped cross section.Moreover, although typically continuous between the ends, each of therails 80 may be segmented or include removed portions as for example atthe ends for placement of the flush mounted end caps.

The width of the rails 80 may be widely varied. For example, they may beone integral piece that extends entirely from one side to the other, orthey may be separate pieces with a gap located therebetween (as shown).The position and cross sectional dimensions and shapes of each of therails may also be widely varied. The size and shape as well as theposition of the rails 80 generally depends on the configuration of thesub assemblies 66. The rails 80 may have the same shape and size or theymay have different shape and size. In most cases, the size and shape isa balance between keeping them as small as possible (for weight andspace requirements) while providing the required reference surface andample support to the subassemblies 66.

To elaborate, the rails 80 define one or more channels 82 that receivethe one or more subassemblies 66. In the illustrated embodiment, therails 80 along with the main body 54 define a pair of channels,particularly an upper channel 82A and a lower channel 82B. The upperchannel 82A receives a first subassembly 66A and the lower channel 8Breceives a second subassembly 66B. It should be noted, however, thatthis is not a limitation and that additional sets of rails 80 may beused to produce additional channels 82. It should also be noted thatalthough only one subassembly 66 is shown for each channel 82 this isnot a requirement and that more than one subassembly 66 may be insertedinto the same channel 82. Moreover, it should be noted that thesubassemblies are not limited to being fully contained with a singlechannel and that portions of a subs assembly may be positioned inmultiple channels. For example, the second subassembly 66B, which ispositioned in the lower channel 82B, may include a protruding portionthat is positioned through the rails 80 and into the upper channel 82A.

The channels 82 generally include an entry point and a final point. Theentry point represents the area of the channel 82 that initiallyreceives the subassemblies 66, i.e., the area proximate the ends of themain body 54. The final point, on the other hand represents the area ofthe channel 82 that prevents further sliding movement. The final pointmay for example set the final mount position of the sub assemblies 66within the housing 52. The final point may for example correspond to anabutment stop. The abutment stop may be integral with the main body 54or a separate component. By way of example, the abutment stop maycorrespond to one more posts that are mounted inside the cavity 56 onthe inside surface of the main body 54 at a predetermined distance alongthe longitudinal axis 74.

In order to prevent the subassemblies 66 from sliding once assembled,the interface between the subassemblies 66 and housing 52 may include alocking or securing mechanism. The locking mechanism 86 generallyconsists of two parts, a housing side locking feature and a subassemblyside locking feature that are cooperatively positioned so that when thesubassembly 66 is inserted into the housing 52, the locking featuresengage with one another thus holding the subassembly 66 in its desiredposition within the housing 52. In most cases, the locking features areconfigured to provide quick and easy assembly of the subassembly intothe housing without the use of tools. The locking features maycorrespond to snaps, friction couplings, detents, flexures and/or thelike. Alternatively or additionally, the assemblies 66 may be attachedto the main body 54 with fasteners or adhesives.

In the illustrated embodiment, the subassemblies 66 each include aflexure tab 88 that engages a recess 90 located on an inner surface ofthe main body 54. When the subassembly 66 is slid into the housing 52,the tab 88 snaps into the recess 90 thereby securing the subassembly 66at a predetermined position along the longitudinal axis 74. That is,because the tabs 88 flex, they allow the subassemblies 66 to pass whenpushed into the cavity 76. When the subassemblies 66 pass over therecess 90, the tabs 88 resume their natural position thereby trappingthe subassemblies 66 in the channel 82 between the locking tab/recess88/90 and the abutment stop at the end of the channel 82. Using thisarrangement, the subassemblies 66 are prevented from sliding out of thechannels 82 on their own. In order to remove the subassembly 66, a usersimply lifts the tab 88 away from the recess 90 while pulling on thesubassembly 66. The recess 90 and abutment stop may cooperate to set thefinal position of the subassembly 66 in the cavity 56 of the main body54. For example, the recess and abutment stop may be configured toposition the user interface elements 70A directly behind the windowopening 62 so that a user has full access to the user interface elements70A.

In accordance with one embodiment, the main body 54 including theinternal rails 80 is formed via an extrusion process. The extrusionprocess is capable of producing an integral tube without seams, crack,breaks, etc. As is generally well known, extrusion is a shaping processwhere a continuous work piece is produced by forcing molten or hotmaterial through a shaped orifice, i.e., the extrusion process producesa length of a particular cross sectional shape. The cross sectionalshape of the continuous or length of work piece is controlled at leastin part on the shaped orifice. As the shaped work piece exits theorifice, it is cooled and thereafter cut to a desired length. As shouldbe appreciated, the extrusion process is a continuous high volumeprocess that produces intricate profiles and that accurately controlswork piece dimensions (which can be a necessity for smaller parts).Furthermore, because extrusion has low tooling costs, it is relativelyin expensive when compared to other forming or manufacturing processes.

The main body 54 may be formed from a variety of extrudable materials ormaterial combinations including but not limited to metals, metal alloys,plastics, ceramics and/or the like. By way of example, the metals maycorrespond to aluminum, titanium, steel, copper, etc., and the plasticmaterials may correspond to polycarbonate, ABS, nylon, etc. The materialselected generally depends on many factors including but not limited tostrength (tensile), density (lightweight), strength to weight ratio,corrosion resistance, formability, finishing, recyclability, toolingcosts, and/or the like. The material selected may also depend onelectrical conductivity, thermal conductivity, combustability, toxicity,and/or the like.

In one particular embodiment, the main body 54 including the internalrails 80 is formed from an extruded aluminum tube. Some of the reasonsfor using aluminum over other materials is that it is light weight andstructurally stronger (e.g., it has very good mechanical properties andstrength to weight ratio). This is especially important for hand helddevices. Other reasons for using aluminum include: reduced tooling costs(e.g., injection moldings can be cost prohibitive), it is easilyformable and extruded in a wide variety of shapes including hollowparts, easily machinable thus making it easy to alter the part after theextrusion process, provides a near net shape, offers superior corrosionresistance, it has high scrap value and is routinely reprocessed togenerate new extrusions, and it can be finished using a variety ofmethods including mechanical and chemical prefinishes, anodic coatings,paints and electroplated finishes.

FIG. 2 is a perspective diagram of a handheld computing device 100, inaccordance with one embodiment of the present invention. By way ofexample, the computing device 100 may generally correspond to the device50 shown and described in FIG. 1. The computing device 100 is capable ofprocessing data and more particularly media such as audio, video,images, etc. By way of example, the computing device 100 may generallycorrespond to a music player, game player, video player, camera, cellphone, personal digital assistant (PDA), and/or the like. With regardsto being handheld, the computing device 100 can be operated solely bythe user's hand(s), i.e., no reference surface such as a desktop isneeded. In some cases, the handheld device is sized for placement into apocket of the user. By being pocket sized, the user does not have todirectly carry the device and therefore the device can be taken almostanywhere the user travels (e.g., the user is not limited by carrying alarge, bulky and heavy device). In the illustrated embodiment, thecomputing device 100 is a pocket sized hand held music player thatallows a user to store a large collection of music. By way of example,the music player may correspond to the iPod series MP3 players, and moreparticularly the iPod mini manufactured by Apple Computer of Cupertino,Calif.

As shown, the computing device 100 includes a housing 102 that enclosesand supports internally various electrical components (includingintegrated circuit chips and other circuitry) to provide computingoperations for the device. The integrated circuit chips and othercircuitry may include a microprocessor, hard drive, Read-Only Memory(ROM), Random-Access Memory (RAM), a battery, a circuit board, andvarious input/output (I/O) support circuitry. In addition to the above,the housing 102 may also define the shape or form of the device 100. Inthis particular embodiment, the housing 102 extends longitudinally andhas a pill like cross section. The size and shape of the housing 102 ispreferably dimensioned to fit comfortably within a user's hand. In oneparticular embodiment, the housing is formed from an extruded materialsuch as aluminum thereby providing a seamless look along the length ofthe device 100. That is, unlike conventional housings, the housing 102,particularly the main body, does not include any breaks between the topand bottom ends thereby making it stronger and more aestheticallypleasing.

The computing device 100 also includes a display screen 104. The displayscreen 104, which is assembled within the housing 102 and which isvisible through an opening 106 in the housing 102, is used to display agraphical user interface (GUI) as well as other information to the user(e.g., text, objects, graphics). By way of example, the display screen104 may be a liquid crystal display (LCD). In some cases, the housing102 may include a window, which is positioned in the opening in front ofthe display in order to protect the display from damage. The window istypically formed from a clear material such as clear polycarbonateplastic.

The computing device 100 also includes one or more input devices 108configured to transfer data from the outside world into the computingdevice 100. The input devices 108 may for example be used to performtracking/scrolling, to make selections or to issue commands in thecomputing device 100. By way of example, the input devices 108 maycorrespond to keypads, joysticks, touch screens, touch pads, trackballs, wheels, buttons, switches, and/or the like. In the illustratedembodiment, the computing device 100 includes a touch pad 108A and oneor more buttons 108B, which are assembled within the housing 102 andwhich are accessible through a second opening 110 in the housing 102.

The touch pad 108A generally consists of a touchable outer surface 111for receiving a finger for manipulation on the touch pad 100A. Althoughnot shown, beneath the touchable outer surface 111 is a sensorarrangement. The sensor arrangement includes a plurality of sensors thatare configured to activate as the finger passes over them. In thesimplest case, an electrical signal is produced each time the fingerpasses a sensor. The number of signals in a given time frame mayindicate location, direction, speed and acceleration of the finger onthe touch pad, i.e., the more signals, the more the user moved his orher finger. In most cases, the signals are monitored by an electronicinterface that converts the number, combination and frequency of thesignals into location, direction, speed and acceleration information.This information may then be used by the device 100 to perform thedesired control function on the display screen 104.

The position of the touch pad 108A relative to the housing 102 may bewidely varied. For example, the touch pad 108A may be placed at anyexternal surface (e.g., top, side, front, or back) of the housing 102that is accessible to a user during manipulation of the device 100. Inmost cases, the touch sensitive surface 101 of the touch pad 108A iscompletely exposed to the user. In the illustrated embodiment, the touchpad 108A is located in a lower, front area of the housing 102.Furthermore, the touch pad 108A may be recessed below, level with, orextend above the surface of the housing 102. In the illustratedembodiment, the touch sensitive surface 111 of the touch pad 108A issubstantially flush with the external surface of the housing 102.

The shape of the touch pad 108A may also be widely varied. For example,the touch pad 108A may be circular, rectangular, square, oval,triangular, and the like. In the illustrated embodiment, the touch pad108A is circular. Circular touch pads allow a user to continuously swirla finger in a free manner, i.e., the finger can be rotated through 360degrees of rotation without stopping. Furthermore, the user can rotatehis or her finger tangentially from all sides thus giving it more rangeof finger positions. For example, when the device 100 is being held, aleft handed user may choose to use one portion of the touch pad 108Awhile a right handed user may choose to use another portion of the touchpad 108A. More particularly, the touch pad is annular, i.e., shaped likeor forming a ring. When annular, the inner and outer perimeter of theshaped touch pad defines the working boundary of the touch pad.

The buttons 108B are configured to provide one or more dedicated controlfunctions for making selections or issuing commands associated withoperating the device 100. By way of example, in the case of a musicplayer, the button functions may be associated with opening a menu,playing a song, fast forwarding a song, seeking through a menu and thelike. In most cases, the button functions are implemented via amechanical clicking action although they may also be associated withtouch sensing similar to the touch pad 108A. The position of the buttons108B relative to the touch pad 108A may be widely varied. For example,they may be next to one another (center or peripheral), spaced apart orintegrated into a single unit. Several touch pad/button arrangements,which may be used in the device 100, are described in greater detail inpending patent application Ser. Nos. 10/643,256, 10/188,182, 10/722,948,which are all herein incorporated by reference.

The computing device 100 also includes one or more switches 112including power switches, hold switches, and the like. The power switchis configured to turn the device 100 on and off, and the hold switch isconfigured to activate or deactivate the touch pad 108A and/or buttons108B. This is generally done to prevent unwanted commands by the touchpad 108A and/or buttons 108B, as for example, when the device 100 isstored inside a user's pocket. Like the touch pad 108A and buttons 108B,the switches 112 are accessible through a third opening 114 in thehousing 102.

The device 100 may also include one or more connectors 116 fortransferring data and/or power to and from the device 100. In theillustrated embodiment, the device 100 includes an audio jack 116A, adata port 116B and a power port 116C. The audio jack 116A allows audioinformation to be outputted from the device 100. The data port 116Ballows data to be transmitted and received to and from a host devicesuch as a general purpose computer (e.g., desktop computer, portablecomputer). The data port 116B may be used to upload or down load audio,video and other image data to and from the device 100. For example, thedata port 116B may be used to download songs and play lists, audiobooks, ebooks, photos, and the like into the storage mechanism of thecomputing device 100. The power port 116C, on the other hand, allowspower to be delivered to the computing device 100. In some cases, thedata port 116B may serve as both a data and power port thus replacing adedicated power port 116C. A data port such as this is described ingreater detail in pending U.S. patent application Ser. No. 10/423,490,which is herein incorporated by reference.

FIGS. 3A and 3B are diagrams of a hand held computing device 150, inaccordance with one embodiment of the present invention. FIG. 3A isperspective diagram showing the computing device 150 in its assembledform, while FIG. 3B is an exploded perspective diagram showing thecomputing device 150 in its unassembled form. The computing device 150may generally correspond to the computing device 100 shown and describedin FIG. 2.

The computing device 150 includes a housing 152, which serves to supportthe internal components of the computing device 150 in their assembledposition within the device 150. The housing 152 includes severalcomponents including a seamless enclosure 154, a bottom end cap 156 anda top end cap 158. The seamless enclosure 154 extends along alongitudinal axis 160, and includes an internal lumen 162 which is sizedand dimension for receipt of the internal components of the computingdevice 150 through a first open end 164 and a second open end 166opposite the first open end 164. The end caps 156 and 158 cover the openends 164 and 166 of the seamless enclosure 154 in order to provide afully contained housing 152. Although the end caps 156 and 158 can beapplied in a variety or ways, in this particular embodiment, each of theend caps 156 and 158 includes a shape that coincides with the internalshape of the seamless enclosure 154 such that they may be inserted intothe open ends, i.e., the outer periphery of the end caps 156, 158matches the inner periphery of the lumen 162. Furthermore, the end caps156 and 158 are positioned to be flush with the bottom 170 and topsurfaces 172 of the seamless enclosure 154 thereby forming a housing 152with a substantially uniform appearance.

In order to help guide at least a portion of the internal components totheir desired position within the seamless enclosure 154, the seam lessenclosure 154 includes an internal rail system 176 including a pair ofrails 177 that protrude out the inner sides of the seamless enclosure154. The two rails 177, which are similarly shaped, are placed in anopposed relationship directly across from one another. The rails 177provide reference surfaces for receiving and supporting some portion ofthe internal components. The portion of the internal components thatengages the rails 177 is typically an edge of the internal components.The internal rail system 176 is integrally formed with the seamlessenclosure 154. By integral, it is meant that the seamless enclosure 154and the rail system 176 are formed from a single piece of material.

In fact, the seamless enclosure 154 along with integrally formedinternal rails 176 are preferably formed from an extrusion process. Theextrusion process produces the desired cross section in a continuoustube, which can be cut to form a seamless enclosure 154 including theinternal rails 176 with a desired length. That is, the seamlessenclosure 154 including the internal rails 176 is formed from anelongated continuous extruded tube that has been cut to a desiredlength. As should be appreciated, the features of the internal rail 176are extruded along with the seamless enclosure 154 thereby forming railsthat have the same length as the seamless enclosure, i.e., the extrusionprocess produces rails that extend from the top to the bottom end of theseamless enclosure.

Although the extrusion process allows for a variety of materials, inthis particular embodiment, the continuous tube is formed from a metalmaterial and more particularly from aluminum (or some other materialthat has similar properties to aluminum). The end caps 156 and 158, onthe other hand, are formed from a plastic material such as ABS using amanufacturing process such as injection molding.

Moving along, the internal components of the computing device 150include a printed circuit board 180 that contains various integratedcircuit chips and other circuitry that provide computing operations forthe computing device 150. The printed circuit board 180 may for exampleinclude a microprocessor 182, memory 184, a data port 186, and a switch188. Although not shown, the printed circuit board 180 may also containinterconnecting circuitry and related components that help tooperatively couple the various internal components together. In order toprovide access to some of these components, the top end cap 158 includesan opening 189A for the switch 188 and the bottom end cap 156 includesan opening 189B for the data port 186. As shown, the switch 188 mayinclude a switch cap 191 that is snapped onto the switch 188 after thetop end cap 158 is finally assembled.

The internal components of the computing device 150 also include adisplay 190 such as for example a liquid crystal display. The liquidcrystal display 190 is mounted on the front of the printed circuit board180. The LCD 190 may be mounted to the PCB 180 using a variety oftechniques. By way of example, the LCD 190 may include locking tabs thatsnap onto the printed circuit board 180 in order to secure the LCD 190thereto. Alternatively, the LCD 190 may be a stand alone assembly, i.e.,floating rather than mounted to the PCB 180. In either case, the LCD 190is operatively coupled to the printed circuit board 180 and its variouscomponents. This may for example be accomplished through a flex circuitconnector that couples to a connector located on the printed circuitboard 180.

In order to provide visible access to the display 190, the seamlessenclosure 154 includes an access opening 192 having a shape thatcoincides with the shape of the viewing area of the LCD 190. The accessopening 192 may be formed by processes such as machining, drilling,cutting, punching and/or the like. In most cases, a clear window 194(typically formed from plastic) is positioned in the access opening 192in front of the LCD 190 in order to protect the LCD 190 from damage. Infact, when assembled, the window 194 may be considered a portion of thehousing 152. The window 194 may be attached to the seamless enclosure154 using a variety of techniques including but not limited tofasteners, snaps, adhesives, etc. In the illustrated embodiment, thewindow 194 includes a raised section 196 that sits in the opening 192and that is either substantially flush or recessed with the outersurface of the seamless enclosure 154 so that it does not protrude abovethe outer surface and a flange section 198 having an adhesive layer thatsecures the window 194 to the inner surface of the seamless enclosure154. By having the window flush or recessed, scratching of the window issubstantially avoided.

The internal components of the computing device 150 also include a harddrive 200. The hard drive 200, which is located at the rear of theprinted circuit board 180, is operatively coupled to the printed circuitboard 180 and its various components. This may for example beaccomplished through a flex circuit connector that couples to aconnector located on the printed circuit board 180. The hard drive 200may be mounted (as shown) or it may be free floating relative to the PCB180. Although not a requirement, the hard drive 200 may be surrounded bya plurality of bumpers 202 that serve to protect the hard drive 200 whenassembled, i.e., the bumpers 202 help to prevent shocks to the harddrive 200. They also may provide a surface that helps retain the harddrive 200 within the housing 152 (e.g., friction, compliance, etc.). Asshould be appreciated, the hard drive gives the device massive storagecapacity unlike flash based devices. By way of example, the hard drivemay have capacities of 5 GB, 10 GB, 15 GB, 20 GB and so on. To cite anexample, when the device is used as a music player, a 20 GB hard drivecan store up to 4000 songs or about 266 hours of music.

The internal components of the computing device 150 also include abattery 206. The battery 206, which is located at the rear of theprinted circuit board 180, is operatively coupled to the printed circuitboard 180 and its various components. This may for example beaccomplished through a connector that couples to a connector located onthe printed circuit board 180. In some cases, the battery may beattached to the backside of the PCB using for example an adhesive suchas double sided tape. In other cases, the battery 206 may be freefloating. By way of example, the battery may correspond to arechargeable lithium polymer battery or a lithium ion prismatic cell.These types of batteries are capable of offering about 10 hours ofcontinuous playtime to the device 150.

The internal components of the computing device 150 also include anaudio subassembly 210. The audio subassembly 210, which is located atthe top of the printed circuit board 180, is operatively coupled to theprinted circuit board 180 and its various components. The audiosubassembly 210 includes at least a small printed circuit board 212 andan audio jack 214. The audio subassembly may also contain variouscircuit components and interconnecting circuitry, which are attached tothe PCB 212. Although the audio subassembly may be free floating, in theillustrated embodiment, the audio subassembly 210 is mechanicallycoupled to the PCB 180 so that the PCB 180 and audio subassembly 210operate as a single unit (i.e., form a single structure). By way ofexample, they may be coupled together using fasteners, adhesives orsnaps.

In one particular embodiment, the audio subassembly 210 is bothoperatively and mechanically coupled to the main printed circuit board180 and its various components through a connector, which is located onthe audio printed circuit board 212, and which couples to a connectorlocated on the main printed circuit board 180. The coupling between theconnectors may include a friction element or mechanical detent thatsubstantially secures the audio subassembly 210 to the printed circuitboard 180. In order to provide access to the audio jack 214 audiosubassembly 210, the top end cap 158 includes an opening 193 having ashape that coincides with the shape of the audio jack 214. In mostcases, the housing of the audio jack 214 is substantially flush with theouter surface of the top end cap 158.

During assembly and referring to the top end of the seamless enclosure154, the integrated system comprising, the PCB 180, LCD 190, hard drive200, battery 206 and audio subassembly 210 is inserted into the lumen156 of the seamless enclosure 154 as a single unit. The printed circuitboard 180 essentially acts as a carrier for placing these componentsinside the housing 152. During assembly, the PCB 180 is inserted in thedirection of the y axis into the space provided by a portion of the sideand bottom surfaces of the seamless enclosure 154 as well as the bottomsurface of the internal rail system 176. This space may be referred toas a channel During insertion, a top surface of the PCB 180 slides alongthe bottom surface of the internal rail system 176 within the space. Asshould be appreciated, the side walls, bottom surface and rails helpconstrain the PCB 180 within the housing 152 during and after insertion.The PCB 180 is typically slid into the seamless enclosure 154 to a depth(y) that places the LCD 190 directly behind the access opening 192.Furthermore, the internal rail system 176 helps locate the PCB 180 andthus the LCD 190 in the direction of the z axis while the side walls ofthe seamless enclosure 154 help locate the PCB 180 and thus the LCD 190in the direction of the x axis.

In order to ensure proper positioning as well as to help secure theintegrated system in place, a top plate 218 may be provided thatprevents further sliding and sets the final position of the integratedsystem. The top plate 218 may be attached to the main PCB 180 or the PCB212 of the audio subassembly 210. The top plate 218 may be attachedusing a variety of techniques including but not limited to fasteners,adhesives, snaps and/or the like. In the illustrated embodiment, the topplate 218 is attached to the PCB 212 of the audio subassembly 210. Whenthe integrated system is slid into the lumen 162, the bottom surface ofthe top plate 218 abuts a recessed area 220 formed in the top surface ofthe seamless enclosure 154. The recessed area 220 may for example beformed by machining a portion of the top surface of the seamlessenclosure 154 (including the rails 177). Once positioned against therecessed area 220, the top plate 218 is attached to the seamlessenclosure 154 using fasteners such as screws 219.

The depth of the top plate 218 generally depends on the desired positionof the top end cap 158. In order to produce a flush top surface, the topplate 218 is typically positioned to a depth corresponding to thethickness of the top plate 218 and the top end cap 158. Once the topplate 218 is secured, the top end cap 158 may be attached thereto. Thetop end cap 158 may be attached to the top plate 218 using fasteners,snaps, adhesives, and/or the like. In order to make assembly easier andto prevent the undesirable look of fasteners, the top plate 218 mayinclude several retaining features for receiving tabs located on theinside surface of the top end cap 158. When the top end cap 158 engagesthe top plate 218, the tabs are inserted into the retaining featuresthereby securing the top end cap 158 to the top plate 218 (via asnapping action).

In one embodiment, the audio subassembly 210 includes a positioningadjustment portion (not shown) configured to provide position reliefwhen attaching the top plate 218 to the seamless enclosure 154. That is,the adjustment portion allows some degree of tolerance or play so thatthe top plate 218, which is connected to the integrated system via theaudio subassembly 210, can be precisely placed relative to the seamlessenclosure 154. The adjustment portion may be separate component or beintegrally formed with the PCB 212. When separate, the adjustmentportion may be or include a compliant member, a flexure, a mechanicalmechanism and/or the like. When integral, the adjustment portion may bea flexure formed from the PCB 212. In particular, the adjustment portionmay be a tab that has been partially cut away from the PCB 212 therebyenabling it to flex or bend.

The internal components of the computing device 150 also include aninput assembly 230. The input assembly 230 may be widely varied. Theinput assembly generally depends on the type of device. In theillustrated embodiment, the input assembly 230 includes a touch pad 232and a center switch 234 positioned on a frame 236. The switch 234 is aportion of a button, which may be actuated by a user to perform actionsin the device 150. Although the input device 230 is structurallyseparated from the printed circuit board 180, it is operatively coupledto the printed circuit board 180 and its various components. This may beaccomplished for example through a flex circuit connector that couplesto a connector located on the printed circuit board 180. This connectionis typically made after the PCB 180 and input device 230 have beeninserted into the seamless enclosure 154.

In some cases, the touch pad 232 is capable of moving relative to theframe 236 in order to actuate additional mechanical switches housedwithin the frame 236. Each of the switches represents a button, whichmay be actuated by a user. By way of example, the input assembly 230 maycorrespond to any of those input devices disclosed in U.S. patentapplication Ser. No. 10/643,256, which is herein incorporated byreference.

In order to provide user access to the input assembly 230, the seamlessenclosure 154 includes an access opening 237 having a shape thatcoincides with the shape of the touch pad 232. Like the first accessopening 192, the second access opening 237 may be formed from processes(individually or in combination) such as machining, drilling, cutting,punching and/or the like. In most cases, a button cap 238 and cover 239is positioned in the access opening 237 in front of the touch pad 232and switch 234 in order to seal the device 150 and protect the touch pad232 and switch 234 from damage. The cover 239 is generally sized forplacement in the access opening 237 and to provide a surface that issubstantially flush with the outer surface of the seamless enclosure154. The cover 239 is typically attached to the touch pad 232 using anadhesive. The button cap 238 typically includes a flange potion that istrapped between the cover 239 and the input assembly 230 therebysecuring the button cap 238 to the input assembly 230.

During assembly and referring to the bottom end of the seamlessenclosure 154, the input assembly 230 is inserted into the lumen 156 ofthe seamless enclosure 154. The frame 236 acts as a carrier for placingthe input assembly 230 inside the housing 152. During assembly, theinput assembly 230 is inserted in the direction of the y axis into thespace provided by a portion of the side and top surfaces of the seamlessenclosure 154 as well as the top surface of the internal rail system176. This space may be referred to as a channel. During insertion, abottom surface of the frame 236 slides along the top surface of theinternal rail system 176 within the space. As should be appreciated, theside walls, top surface and rails help constrain the input assembly 230within the housing 152 during and after insertion. The input assembly230 is typically slid into the seamless enclosure 154 to a depth (y)that places the touch pad 232 directly behind the access opening 237.The depth may be set by posts located inside the seamless enclosure. Inthe illustrated embodiment, the window 193 includes a pair of abutmentstops 240 that prevents further sliding and sets the final position ofthe input assembly 230 in the y direction. Furthermore, the internalrail system 176 helps locate the touch pad 232 and switch 234 in thedirection of the z axis while the side walls of the seamless enclosure154 help locate the touch pad 232 and switch 234 in the direction of thex axis.

In order to ensure proper positioning as well as to help secure theinput assembly 230 in place, the input assembly 230 may include alocking feature that locks the input assembly 230 in place when theinput assembly 230 is finally inserted into the seamless enclosure. Inone embodiment, the locking feature is in the form of a tab 242 thatsnaps into a recess located on the inner surface of the seamlessenclosure 154. The recess may be formed by machining a groove in theinner surface of the seamless enclosure 154 at a position that coincideswith the input assembly 230 when it is finally inserted.

Like the top end, the bottom end may include a structural plate, i.e.,bottom plate 244. The bottom plate 244 is configured to act as areference support surface for the bottom end cap 156. It may also act asa reference surface for the input assembly 230 or the main systemassembly. The bottom plate 244 may be connected to the seamlessenclosure 154 and/or the input assembly 230. The bottom plate 244 may beattached using a variety of techniques including but not limited tofasteners, adhesives, snaps and/or the like. By way of example, thebottom plate 244 may be connected in a manner similar to the top plate(attached to the input assembly and inserted into a recess).

Alternatively, as shown in the Figure, the bottom plate 244 may includeretaining features 246 that snap into recesses formed in the innersurface of the seamless enclosure 154 thereby mechanically securing thebottom plate 244 to the seamless enclosure 154. The recesses may beformed by machining grooves in the inner surface of the seamlessenclosure 154 at a position that coincides with the retaining features246 when the bottom plate 244 is inserted in the seamless enclosure 154.During assembly, the retaining features 246 are flexed inwardly, and thebottom plate 244 is placed inside the seamless enclosure 154. Once thebottom plate 244 is correctly positioned next to the recesses, theretaining features 246 are unflexed outwardly thereby causing them to beoutwardly extended into the recesses, i.e., the retaining features 246are received by the recesses. A tool may be required to flex theretaining features in a manner analogous to retaining rings. Unlikeretaining rings, however, the bottom plate is not circular, and spansthe inside of the enclosure to support internal and external parts.Furthermore, the bottom plate is fixed in place and cannot rotate ascircular retaining rings thus providing a reference surface in more thanjust the y direction, i.e., the bottom plate provides a referencesurface in the x, y and z directions. This enables the bottom plate tofixedly support the end cap.

The depth of the bottom plate 244 generally depends on the desiredposition of the bottom end cap 156. In order to produce a flush bottomsurface, the bottom plate 244 is typically positioned to a depthcorresponding to the thickness of the bottom plate 244 and the bottomend cap 156. Once the bottom plate 244 is secured, the bottom end cap156 may be attached thereto. The bottom end cap 156 may be attached tothe bottom plate using fasteners, snaps, adhesives, and/or the like. Inorder to make assembly easier and to prevent the undesirable look offasteners, the bottom plate 244 may include several retaining featuresfor receiving tabs located on the inside surface of the bottom end cap156. When the bottom end cap 156 engages the bottom plate 244, the tabsare inserted into the retaining features thereby securing the bottom endcap 156 to the bottom plate (via a snapping action).

The bottom plate may be formed from a variety of materials such asmetals and plastics. The material that is selected typically offers abalance between resistance to deformation so as to provide a structuralsurface and bendability so that the flexure arms can be flexed duringinstallation. In the illustrated embodiment, the bottom plate is formedfrom stainless steel, and more particularly high hardness stainlesssteel.

FIG. 4, which is top view, in cross section of the assembled device 150,shows the position of the various components of the integrated systeminside the housing 152 and more particularly the seamless enclosure 154.As shown, the top surface at the edge of the printed circuit board 180abuts the bottom surface of the rails 177. Furthermore, the battery 206and hard drive 202 are contained within the lower channel formed by therails, sides and back surface of the seamless enclosure 154. In mostcases, there is a snug fit between these components and the surroundingportions of the seamless enclosure 154 so as to help hold the integratedsystem in place. Moreover, the LCD 190 protrudes above the rails 177through a gap formed between the rails 177 so that it is positioneddirectly underneath the window 194. In some cases, the gap may bedimensioned to form a snug fit between the LCD and rails to better alignthe LCD with the opening, i.e., the rails provide a reference surfacefor the LCD in the x direction.

FIG. 5, which is bottom view, in cross section of the assembled device150, shows the position of the input assembly 230 inside the housing152, and more particularly the seamless enclosure 154. As shown, thebottom surface at the edge of the frame 236 abuts the top surface of therails 177. Furthermore, most of the input assembly 230 is containedwithin the upper channel formed by the rails, sides and surface of theseamless enclosure 154. In most cases, the input assembly 230 is sizedand dimensioned to fit snuggly inside the upper channel. A small portionof the frame (or other component of the input assembly 230) may bepositioned within the gap formed between the two rails 177.

FIGS. 6A-6C show the insertion and mounting of the input assembly 230inside the seamless enclosure 154. As shown in FIG. 6A and 6B, the inputassembly 230 is inserted into the bottom end of the seamless enclosure154. In particular, the front edge of the input assembly 230 is placedwithin the upper channel against the rails 177, and the input assembly230 is slid along the rails 177 into the seamless enclosure 154. Asshown in FIG. 6C, when the input assembly 230 nears its final positionin the y direction, the tab 242 on the rear of the input assembly 230snaps into a recess 256 located on the inner top surface of the seamlessenclosure 154 thereby securing the input assembly 230 between this pointand the abutment stops 240 located on the window 194. The positions ofthe abutment stop 240 and recess 256 are preferably positioned such thatthe tab 242 engages the recess 256 as the input assembly 230 pressesagainst the abutment stop 240. This particular arrangement helps preventany subsequent movement of the input assembly 230, i.e., locks it intoplace (in the y direction).

FIGS. 7A and 7B show the bottom plate 244 in its unassembled andassembled positions. The bottom plate 244 includes a body 261 and aplurality of flexure arms 246. The body 261 is typically configured tofill the available space between the opposing sets of retaining arms 256so as to produce a more rigid structure for supporting the variouscomponents enclosed within or attached to the enclosure 154. The flexurearms 246, which extend from the body 261, are configured to bend intowards the body 261 when a force F is applied to the flexure arms 246.In some cases, the interface between the body and the flexure armsincludes a radius. The radius may be adjusted to tune the stiffness ofthe flexure arms. The force F may for example be provided by a pinchingtool that engages holes 262 located in each of the flexure arms 246.

Both the body and the arms are configured to cooperate to form the shapeof the bottom plate. The shape may be widely varied although the shapeis generally configured to be non circular so as to provide a betterreference surface (e.g., substantially rectangular). In fact, the shapemay coincide with the shape of the lumen found in the enclosure.

The bottom plate 244 may be formed from a variety of structuralmaterials including metals and plastics. By way of example, the bottomplate 244 may be formed from stamping a sheet of metal (e.g., steel) orfrom molding a piece of plastic.

As shown in FIG. 7B, the bottom plate 244 is positioned inside the lumen162 of the seamless enclosure 154. In particular, the flexure arms 246are retained within slots 263 located on the inside surface of theseamless enclosure 154. In fact, the flexure arms may include outwardprotrusions that provide a better interface between the flexure arms andthe slots. The bottom plate 244, which is designed to receive the bottomend cap 156, is positioned at the end of the seamless enclosure 154 soas to produce a reference support surface for the bottom end cap 156. Inessence, the bottom plate 244 when retained acts as an extension of theseamless enclosure 154. The depth of the bottom plate 244 is typicallyconfigured to place the outer surface of the bottom end cap 244substantially flush with the bottom surface 264 of the seamlessenclosure 154. The bottom plate 244 may include various features 266 forreceiving locking tabs located on the bottom end cap 156. As should beappreciated, the features may be openings or voids that receive snaps onthe bottom of the end cap, i.e., the snaps snap into the openingsthereby securing the bottom end cap to the bottom plate. The bottomplate 244 may also include an opening 267, which provides a clearancefor the connector 186.

FIG. 8 is a diagram of the audio subassembly 210, in accordance with oneembodiment of the present invention. As shown in FIG. 8A, the PCB 212 isdivided into a flexure portion 270, a first base portion 272 and asecond base portion 274. This may be accomplished by cutting a groove inthe PCB 212. The audio jack 214 is attached to the first base portion272 and the top plate 218 is attached to the audio jack 214. The secondbase portion 274 includes a connector 276 that mates with a connector onthe main PCB 180 in order to operatively and mechanically couple theaudio subassembly 210 to the main PCB 180, i.e., form a single unit. Theflexure portion 270 is positioned between the first and second baseportions 272 and 274. The flexure portion 270 allows the first baseportion 272 to move relative to the second base portion 274. The flexure270 causes the first base portion 272 and thus the top plate 218 tofloat relative to the main PCB 180 while still being constrainedthereto. As shown in FIGS. 8B and 8C, the flexure portion 270 is capableof flexing or bending so that the first base portion 272 can shiftrelative to the second base portion 274 thereby allowing the top plate218 to be correctly aligned with the recess 220 of the seamlessenclosure 154.That is, the flexure 270 allows the top plate 218 to shiftinto mating engagement with the recess 220 of the seamless enclosure 154thereby producing a tight fit between the top plate 218 and the seamlessenclosure 154.

FIGS. 9A-9H are various diagrams of the seamless enclosure 154. Asshown, the seamless enclosure 154 includes a planar front surface 280, aback planar surface 282 and rounded sides 284. The access openings 192and 237 for the LCD 190 and input assembly 230 are located in the frontplanar surface 280. The seamless enclosure 154 also includes a lumen 162therethrough that defines openings at each of the ends of the seamlessenclosure 154. The rails 177, which extend substantially through thelumen 162, are located in an opposed relationship inside the lumen 162.The rails 177 protrude away from the sides of the lumen 162 and arepositioned closer to the front planar surface 280 than the back planarsurface 282. The end at the top of the seamless enclosure 154 includes arecess 220 for receiving the top plate 218 and top end cap 158. Therecess 220 essentially forms a lip to which the top plate 218 issecured. The end at the bottom of the seamless enclosure 154 includes acut out section 290for receiving the bottom plate 244 and the bottom endcap 156. The cut out 290 is formed by shortening the ends of the rails177. This end also includes a plurality of slots 263 for receiving theflexure arms 246 of the bottom plate 244.

FIG. 10 is a method of manufacturing an electronic device 340, inaccordance with one embodiment of the present invention. The electronicdevice may generally correspond to any of those previously described.The method generally includes several operations including: theformation of the housing 342, the assembly of the internal componentsincluding the main system assembly 244 and the touch pad assembly 346,and the final assembly of the housing 348.

Referring first to the formation of the housing 342, the operationstarts with block 352 where a tube having internal rails is extruded.Following block 352, the operation proceeds to block 354 where theextruded tube is cut to a desired length. Following block 354, theoperation proceeds to block 356 where the access openings are formed inthe extruded tube. By way of example, the access opening may beassociated with a user interface of the electronic device. Followingblock 356, the operation proceeds to block 358 where a recess is formedinto a top surface of the extruded tube. Following block 358, theoperation proceeds to block 360 where one or more threads are formed inthe recess at the top surface of the extruded tube. Following block 360,the operation proceeds to block 362 where a portion of the internalrails are removed from the bottom surface of the extruded tube.Following block 362, the operation proceeds to block 364 where slots areformed in the area where the internal rails were removed.

Referring to the assembly of the various components inside the tube 344,the operation starts with block 366 where a window is mounted in one ofthe access openings. This may for example be accomplished using anadhesive such as glue or tape. Following block 366, the operationproceeds to block 368 where a main system assembly is inserted into thetop end of the extruded tube along the lower surface of the internalrails. The main system assembly is typically sized and dimensioned forsliding receipt between the lower surface of the internal rails and theside and back surface of the extruded tube. The main system assemblygenerally includes a printed circuit board, which acts as the carrierfor several components including: system electronics (e.g.,microprocessor and memory); an LCD; a battery; I/O assemblies (audioassembly, data port assembly); etc. Following block 368, the operationproceeds to block 370 where the main system assembly is mounted to theextruded tube. This is generally accomplished through a top plate thatis attached to the main system assembly. When the main system assemblyis finally inserted into the extruded tube, the top plate pressesagainst the upper surface of the recess thereby setting the position ofthe main system assembly in its desired position along the longitudinalaxis of the extruded tube. The top plate is then attached to theextruded tube via screws and the previously formed threads.

Referring to the assembly of the touch pad assembly 346, the operationstarts with block 372 where the touch pad assembly is inserted into thebottom end of the extruded tube along the upper surface of the internalrails. The touch pad assembly is typically sized and dimensioned forsliding receipt between the upper surface of the rail and the side andfront wall of the extruded tube. When the touch pad assembly is finallyinserted into the extruded tube, the top surface of the touch padassembly presses against a pair of abutment stops located at the bottomend of the window thereby setting the position of the touch pad assemblyin its desired position along the longitudinal axis of the extrudedtube. In particular, the touch pad of the touch pad assembly ispositioned directly behind the second access opening.

Following block 372, the method proceeds to block 374 where the touchpad assembly is operatively coupled to the main system assembly. By wayof example, a simple connector connection may be made or a solderconnection can be made. In the illustrated embodiment, the touch padassembly includes a flex connector that couples to a connector locatedon the PCB. Following block 374, the operation proceeds to block 376where a button cap and label is situated over the touch pad of the touchpad assembly. The button cap is disposed over a center switch and thelabel is disposed over an edge of the button cap as well as the touchpad. The label is typically attached to the touch pad using an adhesive.In most cases, the label is positioned in the recessed area formed bythe touch pad and the edge of the access opening. The label thereforehelps to secure the touch pad assembly in its desired position withinthe extruded tube. Although not a requirement, the top surface of thelabel is typically positioned substantially flush with the outer surfaceof the extrude tube.

Referring to the final assembly of the device, the operation starts withblock 378 where the snap plate is inserted into the slotted bottom endof the extruded tube thereby securing the snap plate to the extrudedtube. Following block 378, the operation proceeds to block 380 where thebottom end cap is mounted to the bottom end of the extruded tube. Thisis generally accomplished by positioning the bottom end cap in therecessed area formed by the snap plate and the inner surface of theextruded tube, and snapping tabs located on the bottom end cap into thesnap plate thereby securing the bottom end cap to the snap plate. Inmost cases, the outer surface of the bottom end cap is made flush withthe bottom surface of the extruded tube. Following block 380, theoperation proceeds to block 382 where the top end cap is mounted to thetop end of the extruded tube. This is generally accomplished bypositioning the top end cap in the recessed area formed by the top plateand the inner surface of the extruded tube, and snapping tabs located onthe top end cap into the top plate thereby securing the top end cap tothe top plate. It should be pointed out that during insertion of the topend cap into the recessed area, a protruding member of the audioassembly is inserted through an opening in the top end cap. Because theaudio assembly includes a flexure, the protruding member has a smallamount of tolerance or play that allows for easy placement through theopening. Once the top end cap is attached, the switch cap may be placedon the switch assembly through another opening in the top end cap.

While this invention has been described in terms of several preferredembodiments, there are alterations, permutations, and equivalents, whichfall within the scope of this invention. For example, although theinvention is primarily directed at an integrally formed internal railsystem, in some cases the internal rail system may be a separatecomponent that is attached within the main body. It should also be notedthat there are many alternative ways of implementing the methods andapparatuses of the present invention. For example, although an extrusionprocess is preferred method of manufacturing the integral tube, itshould be noted that this is not a limitation and that othermanufacturing methods may be used (e.g., injection molding). It istherefore intended that the following appended claims be interpreted asincluding all such alterations, permutations, and equivalents as fallwithin the true spirit and scope of the present invention.

What is claimed is:
 1. A method of manufacturing a handheld device,comprising: forming an elongated housing extending along a longitudinalaxis, wherein the elongated housing has a first open end opposite asecond open end, the elongated housing defining an internal lumenreceiving at least one electronic operational component of the handhelddevice, the internal lumen including a lumen locking feature disposedwithin the internal lumen; and securing a printed circuit board to theelongated housing by inserting a printed circuit board into the internallumen such that a locking feature of the printed circuit board engagesthe lumen locking feature to secure the printed circuit board directlyto the elongated housing and to prevent sliding of the printed circuitboard when the printed circuit board is in its locking position withinthe internal lumen.
 2. The method as recited in claim 1, wherein theprinted circuit board is secured directly to the elongated housingwithout use of a tool.
 3. The method as recited in claim 1, furthercomprising positioning another electronic operational component on theprinted circuit board prior to securing the printed circuit board to theelongated housing such that the printed circuit board acts as a carrierfor the electronic operational component.
 4. The method as recited inclaim 1, wherein the internal lumen includes rails for guiding anoperational component to a desired position within the internal lumen.5. The method as recited in claim 4, wherein the rails define an upperchannel and a lower channel inside the internal lumen, the upper channelreceiving a first operational component, the lower channel receiving asecond operational component, the first and second operationalcomponents being located relative to a front wall of the elongatedhousing via the rails.
 6. The method as recited in claim 1, furthercomprising closing the first and second open ends with a first end capat the first open end of the elongated housing and a second end cap atthe second open end of the elongated housing, the first end cap defininga top wall of the handheld device, the second end cap defining a bottomwall of the handheld device, the end caps cooperating with the elongatedhousing to form a fully contained housing of the handheld device.
 7. Themethod as recited in claim 1, wherein the lumen locking featurecomprises a recess in a wall of the internal lumen and the lockingfeature of the printed circuit board comprises a flexure tab.
 8. Themethod as recited in claim 1, wherein forming the elongated housingcomprises extruding.
 9. A method of manufacturing a handheld computingdevice, comprising: forming an enclosure including an integral housingmember that extends along a longitudinal axis and that includes a cavitytherein and one or more access openings, the integral housing memberdefining at least a front wall, side walls and back wall of theenclosure, the front wall having a substantially planar front surface;inserting a user interface sub-system into the cavity through an openend of the integral housing member; and securing the user interfacesub-system directly to the integral housing member by engaging asub-system locking feature on the user interface sub-system with ahousing locking feature disposed entirely within the cavity such thatthe user interface sub-system is prevented from sliding within thecavity when the user interface sub-system is in its locking positioninside the cavity and the user interface sub-system is presented throughan access opening.
 10. The method as recited in claim 9, wherein theuser interface sub-system is secured directly to the integral housingmember without use of a tool.
 11. The method as recited in claim 9,wherein securing the user interface sub-system further comprises slidingthe user interface sub-system along a pair of internal rails that extendparallel to the longitudinal axis and that protrude inwardly into thecavity from opposing side walls of the integral housing member.
 12. Themethod as recited in claim 9, wherein the integral housing member isformed from a tube having a substantially seamless construction with asubstantially uniform cross section along the longitudinal axis of thetube.
 13. The method as recited in claim 9, wherein the housing lockingfeature comprises a recess in an inner wall of the housing member, andthe sub-system locking feature of the user interface sub-systemcomprises a flexure tab.
 14. The method as recited in claim 9, whereinthe user interface sub-system includes a memory component that stores acollection of music and a processing component that plays the musicstored in the memory component.
 15. A method of manufacturing a handhelddevice, comprising: forming an elongated tube having a first open end, asecond open end opposite the first open end, and at least one accessopening provided on a wall of the elongated tube, the elongated tubedefining an internal lumen which is sized and dimensioned for slidablereceipt of electronic operational components; and securing a printedcircuit board directly to the internal lumen in a locking positionwithin the lumen by sliding the printed circuit board into the internallumen and engaging a component locking feature of the printed circuitboard to a lumen locking feature that is disposed entirely within theinternal lumen.
 16. The method as recited in claim 15, wherein theprinted circuit board is secured directly to the elongated tube withoutuse of a tool and the printed circuit board acts as a carrier for atleast one other electronic operational component.
 17. The method asrecited in claim 15, wherein securing the printed circuit board furthercomprises sliding the printed circuit board along internal rails withinthe internal lumen.
 18. The method as recited in claim 17, wherein therails define an upper channel and a lower channel inside the lumen, theupper channel receiving a first operational component, the lower channelreceiving a second operational component.
 19. The method as recited inclaim 15, wherein the electronic operational components include: atleast one memory component that stores a collection of music; and aprocessing component that plays the music stored in the memorycomponent.
 20. The method as recited in claim 17, wherein the printedcircuit board is part of a main control assembly, the elongated tubedefines a front wall, side walls and a back wall of the handheld device,the front wall including a first access opening and a second accessopening, the rails are a pair of internal protrusions provided onopposed sides of the lumen along the respective side walls of theelongated tube, the internal protrusions being integrally formed withthe elongated tube, and wherein securing the printed circuit boardcomprises inserting the main control assembly into the internal lumen,wherein the main control assembly further comprises a microprocessor anda display connected to the printed circuit board, the main controlassembly being inserted in the internal lumen such that an upper surfaceof the printed circuit board abuts a bottom surface of the rails, thedisplay provided on the upper surface being disposed directly under thefirst access opening; and wherein the method further comprises insertingan input assembly into the internal lumen, the input assembly having aninput device and a frame holding the input device, the input assemblybeing inserted in the lumen such that a lower surface of the frame abutsa top surface of the rails, the input device being disposed directlyunder the second access opening.
 21. The method as recited in claim 20,wherein the main control assembly further includes a memory unit and abattery provided on a lower surface of the printed circuit board. 22.The method as recited in claim 20, wherein the handheld device furthercomprises an audio assembly operatively coupled with the printed circuitboard of the main control assembly.
 23. The method as recited in claim20, wherein the input device includes a touch pad and a switchingbutton.
 24. The method as recited in claim 20, further comprising:providing a first end cap at the first open end of the elongated tube;and providing a second end cap at the second open end of the elongatedtube, wherein the first and second end caps cooperates with theelongated tube to form a fully contained housing of the handheld device.25. The method as recited in claim 15, wherein the lumen locking featurecomprises a recess in an inner wall of the tube and the componentlocking feature of the printed circuit board comprises a tab.